SEAT Workshop Service and Repair Manuals

Removing and installing intake manifold with fuel rail t  Removing → Anchor t  Installing → Anchor After the fuel rail has been removed or renewed, intake manifold flap potentiometer -G336- must be adapted to engine control unit -J623-. For this purpose, select → Vehicle diagnostic, testing and information system VAS 5051 in the „Guided Functions“. Check the tool and equipment equivalence table according to the applicability between Seat / VW / Audi / Skoda → Chapter Special tools and workshop equipment required

t  Pliers for spring-loaded band-type clamps -VAS 6499-, see equivalent → Anchor

t  Longer wrench -T10347-, see equivalent → Anchor Removing   Note t  The injectors can only be accessed after the intake manifold and the fuel rail with the air flow control flap have been removed. t  The combustion chamber ring seal (Teflon) and the O-ring must be renewed. t  Intake manifold - Assembly overview → Chapter t  Fuel rail - exploded view → Chapter   WARNING The fuel system is pressurised. The fuel pressure in the high-pressure part of the injection system must be reduced to a residual pressure prior to opening; for procedure see → Chapter.   Caution Risk of severe damage to the electronic components when disconnecting the battery. Observe the correct procedure for disconnecting the battery → Rep. gr.27.

–  Disconnect battery earth cable -arrow- with ignition switched off.

–  Pull off engine cover panel -arrows-.

–  Separate the vacuum pipe -arrow- to the active carbon deposit. –  Unplug the following connectors. 1 -  Activated charcoal filter solenoid valve 1 -N80- 2 -  From knock sensor 1 -G61- 3 -  From intake manifold flap valve -N316-, fuel pressure sender -G247- and Hall sender -G40- 4 -  From injectors 5 -  Throttle valve control mechanism -J338- 6 -  Intake air temperature sender -G42-

Unplug the electrical connector -1- at Hall sender -G40-.

–  Open hose clip -arrow- securing air intake hose and disconnect hose downwards from throttle valve module -J338-.

–  Disconnect vacuum line -1- at connection -2-. –  Remove crankcase breather hose -3-.   Note

–  Release spring-type clip -top arrow- and detach fuel supply hose from high-pressure pump. –  Unscrew union nut for high-pressure pipe -bottom arrow- at high-pressure pump.   Note t  The fuel system must not be under pressure. t  Use a clean cloth to catch escaping fuel. t  Seal off open connections with clean caps. Make sure no dirt gets into the fuel system.

–  Remove the vacuum pipe -arrow- from the valve for intake manifold flap -N316-.

–  Remove bolt -arrow- for coolant line from intake manifold.

–  Disconnect electrical connector from the fuel pressure sender -G247--1-.

–  Slightly loosen the securing nut -1- and unscrew the bolt -2- out completely.

–  Remove the oil filter -arrow- using the extractor -3417-. –  Screw out the bolts of the intake manifold using the longer wrench -T10347-.   Note For unscrewing the bolts that are difficult to access using the longer wrench -T10347-, the throttle valve module -J338- has to be removed. –  Carefully pull intake manifold and fuel rail slightly away from cylinder head.

–  Only unplug the electrical connector -1- from the intake manifold flap potentiometer -G336- and then remove the intake manifold.   Note t  The injectors can remain in the fuel rail. t  Block off the intake ports with a clean cloth. –  Disconnect intake manifold from fuel rail → Chapter. Installing   Note Ensure that the injector units are correctly fitted. –  Slide the intake manifold on to the pins (lower left and right hand side) on the cylinder head. –  Perform remaining installation in reverse order of removal. l  Tightening torque: refer to intake manifold - exploded view → Chapter l  Tightening torque: Fuel rail - exploded view → Chapter